Laser nozzle comprising an element movable in a gas layer

ABSTRACT

Laser nozzle usable for laser cutting, especially with a fiber or disk laser, comprising: a nozzle body comprising an axial housing passing axially through the nozzle body and comprising a first output orifice located in the front side of the nozzle body; a movable element able to move in translation in the axial housing in the direction of the first output orifice under the effect of a gas pressure acting on the movable element; and an elastic element arranged in the axial housing, between the nozzle body and the movable element, the elastic element exercising an elastic return force on the movable element tending to oppose the translation movement in the axial housing in the direction of the first output orifice.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/356,706, filed May 7, 2014, which is a 371 of InternationalApplication PCT/FR2012052411, filed Oct. 22, 2012, which claims priorityto French Application No. 1160051, filed Nov. 7, 2011, the entirecontents of which are incorporated herein by reference.

BACKGROUND

The invention concerns a laser nozzle usable for laser-beam cutting withthe internal movable element comprising a skirt for concentrating thecutting gas in the cutting kerf, as well as a laser-cutting method usingsaid nozzle, a laser focusing head on which said nozzle is fixed, and alaser cutting installation able to perform said method.

Laser-beam cutting requires the use of a nozzle, generally made fromcopper, the effect of which is to channel the gas and allow the laserbeam to pass.

The nozzles typically have diameters of their outlet orifice of between0.5 and 3 mm for a working distance of between 0.6 and 2 mm.

In order to enable cutting, it is necessary to use high pressures,generally of several bar, in the focusing head in order to enable thegas to enter the kerf so as to drive out the molten metal.

However, a large part of the gas used, typically between 50% and 90%,has no action on the cutting process, that is to say on the expulsion ofthe molten metal, since it starts on the sides of the cutting kerf.

These gas losses are in fact due to the enormous difference between thecross-section of flow of the nozzle orifice and the size of the focalspot. Thus, by way of indication, the cross-section of flow of a nozzlewith an outlet orifice with a diameter of 1.5 mm is 25 times greaterthan the cross-section of the focal spot created by the laser beampassing through this nozzle.

However, if an insufficient proportion of gas is used, cutting defectsthen appear, in particular adherent burrs and/or traces of oxidation.

Attempting to remedy this by reducing the diameter of the nozzle orificeis not ideal since the risk is then taken of having the laser beamstriking the inside of the nozzle and damaging it, which moreover alsoimpairs the cutting quality and/or the performances.

There exist moreover a certain number of documents proposing varioussolutions for attempting to assist the entry of gas into the kerf, forexample EP-A-1669159, JP-A-62006790 and JP-A-61037393.

However, none of these solutions is truly ideal since there is often acomplex architecture to use, with a size greater than that of aconventional nozzle, and/or having limited efficacy.

Some solutions propose in particular to use a laser nozzle comprising amovable element, the end of which is pressed by a spring against thesurface of the part to be cut in order to assist the injection of thecutting gas into the kerf.

The major drawback of these solutions lies in the fact that the forceexerted by the spring in the direction of the metal sheet, added to thepressure of the cutting gas, leads the movable element to exert a highforce on the sheet to be cut. The result is a risk of deformation,scratching or even driving of the metal sheet, which is in generalsimply placed on the table of the industrial cutting machine.

Furthermore, the movable element in contact with the metal sheet isliable to be damaged by burrs, splashing or obstacles forming reliefs onthe surface of the sheet. This reduces the service life of the nozzleand impairs the productivity of the method.

To attempt to remedy this, the document JP-A-7251287 proposes a lasernozzle comprising a movable element and a spring exerting a forcetending to press said element onto the sheet. Furthermore, JP-A-7251287proposes using the force exerted by the cutting gas delivered in thenozzle and escaping under the surface of said element situated oppositethe sheet to be cut in order to cause a slight distancing of the movableelement with respect to the sheet.

However, this solution continues to pose certain problems.

SUMMARY

In particular, an industrial cutting method uses steps during which nocutting gas is delivered by the nozzle, or only a low pressure ofcutting gas supplies the nozzle.

This is particularly the case during piercing of the metal sheet, whichis performed with low gas pressures, typically less than 4 bar, orduring rapid movements of the nozzle above the sheet, at a distanceranging typically from 0.5 mm to a few mm, which are performed withoutcutting gas or beam, in particular when several interleaving parts arecut on the same sheet. To gain in speed and production rate, theseoperations are generally performed by avoiding lifting the device thatsupports the nozzle with respect to its position in the cuttingconfiguration.

In these situations, the solution of JP-A-7251287 does not permitsufficient distancing of the movable element with respect to the sheetand the problems mentioned above are again encountered. Furthermore, themovable element continuously projects outside the nozzle body. Theresult is an increased risk of damage. This also poses a problem in thepiercing phases where an excessively close proximity of the nozzle withthe sheet is to be proscribed because of significant splashings ofmolten metal generated.

The problem that is posed is consequently being able to improve theefficacy of the gas used in laser cutting by increasing the proportionof gas having an action on the expulsion of the molten metal andconsequently reducing the overall quantity of gas used and the pressuregas necessary while limiting the proportion of gas lost. Furthermore,the aim of the present invention is to overcome all or some of thedrawbacks of the devices of the prior art, in particular limiting oreven preventing any risk of scratching, deformation or driving of thecut sheet and damage to the laser nozzle, during the various phases ofan industrial cutting method, in particular the phases not using gas orusing low gas pressures.

The solution of the present invention is a laser nozzle comprising:

-   -   a nozzle body comprising an axial nozzle axially passing through        said nozzle body and comprising a first outlet orifice situated        at the front face of the nozzle body,    -   a movable element arranged in the axial housing of the nozzle        body comprising a front part forming a skirt and an axial        passage with a second outlet orifice emerging at the front part        forming a skirt, said movable element being able to move in        translation in the axial housing in the direction of the first        outlet orifice under the effect of a gas pressure exerted on the        movable element, and    -   an elastic element arranged in the axial housing, between the        nozzle body and the movable element, said elastic element        exerting an elastic return force on the movable element tending        to oppose the translation movement in the axial housing in the        direction of the first outlet orifice,    -   characterised in that the internal profile of said axial passage        of the movable element comprises an upstream portion with a        convergent frustoconical shape, a downstream portion with a        divergent frustoconical shape and an intermediate portion with a        cylindrical shape situated between the upstream portion with a        convergent frustoconical shape and the downstream portion with a        divergent frustoconical shape.

According to circumstances, the nozzle of the invention may comprise oneor more of the following technical features:

-   -   when the movable element moves in translation in the axial        housing in the direction of the first outlet orifice situated at        the front face of the nozzle body, the front part forming a        skirt of the movable element projects outside the axial housing        through the first outlet orifice of the front face of the nozzle        body;    -   the movable element is able to move in translation in the axial        housing until the front part forming a skirt of the movable        element projects outside the axial housing through the first        outlet orifice of the front face of the nozzle body;    -   the bottom of the axial housing of the nozzle body comprises a        shoulder, and the peripheral wall of the movable element        comprises a stop, the elastic element being positioned between        the shoulder and the stop;    -   at least one sealing element is arranged between the nozzle body        and the movable element;    -   said at least one sealing element is arranged in a peripheral        groove provided in the external peripheral wall of the movable        element;    -   the movable element is able to move between several positions        comprising:    -   an idle position in which the skirt of the front part is totally        or almost totally retracted in the axial housing of the nozzle        body, and    -   a working position in which the skirt of the front part totally        or almost totally projects outside the axial housing of the        nozzle body, through the first outlet orifice;    -   the nozzle body is made from an electrically conductive        material, in particular copper, brass or the like;    -   the movable element is formed wholly or partly from an        electrically insulating material;    -   alternatively, the movable element is made from an electrically        conductive material that is resistant to temperature/heat, in        particular copper, brass or the like, said insulating element        comprising at least one insulating interface arranged between        the nozzle and the wall of the movable insert. The insulating        interface is either a sleeve arranged in the nozzle body, or an        insulating cladding carried by the nozzle body or the movable        element.

The invention also relates to a laser focusing head comprising at leastone focusing lens, characterised in that it also comprises a lasernozzle according to one of the preceding claims.

Moreover, the invention also concerns a laser installation comprising alaser generator, a laser focusing head and a laser beam conveying deviceconnected to said laser generator and to said laser focusing head,characterised in that the laser focusing head is in accordance with theinvention.

Preferably, the laser generator is of the CO₂ or YAG type, with fibresor discs.

According to yet another aspect, the invention also relates to a methodfor the laser-beam cutting of a part to be cut, in which a nozzleaccording to the invention, a laser focusing head according to theinvention or an installation according to the invention is used.

Preferably, when a gas flow passes through the axial passage of themovable element of the nozzle, the divergent frustoconical downstreamportion of said movable element is able to produce a leakage of gas,preferably controlled, between the front part of said movable elementand the top surface of the part to be cut in order to form a gaseouslayer under the front part of said movable element, thus opposing thetranslation movement of the movable element and holding the front partof said movable element at a distance of between 0.01 and 0.1 mm fromthe top surface of the part to be cut.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be better understood by means of the followingdescription given with reference to the accompanying figures, amongwhich:

FIG. 1A shows diagrammatically a focusing head of a conventional lasercutting installation,

FIG. 1B shows schematically the size of the laser spot compared with thesize of the nozzle orifice,

FIG. 2 is a diagram in cross-section of the body of a nozzle accordingto the invention,

FIG. 3 is a diagram in cross-section of a nozzle according to theinvention, and

FIG. 4A and FIG. 4B show the nozzle of the invention with the movableelement in two different positions.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1A shows the focusing head 20 of a conventional laser cuttinginstallation, to which there is fixed a conventional laser nozzle 21which has passing through it a focused laser beam and assistance gas(arrow 23) serving to expel the metal melted by the beam out of thecutting kerf 31 formed by the beam 22 in the metal part to be cut 30,for example a steel or stainless steel sheet.

The assistance gas may be an active gas, such as oxygen, air, CO₂ orhydrogen, or an inert gas such as argon, nitrogen or helium, or amixture of several of these active and/or inert gases. The compositionof the gas is chosen in particular according to the nature of the partto be cut.

The beam that impacts the part will melt thereon the metal that will beexpelled below the part by the pressure of the assistance gas.

FIG. 1B shows clearly the cross-section of flow S1 of the orifice 24 ofthe nozzle 21 with respect to the size S2 of the focal spot of the beam22. As can be seen, the cross-section 51 is very much greater than thesize S2 of the focal spot of the beam 22, which, with conventionalnozzles, gives rise to a high consumption of assistance gas, only asmall proportion of which will serve to expel the molten metal out ofthe cutting kerf 31.

In order to considerably reduce the consumption of gas as well as thepressure necessary for cutting, the present invention proposes animproved laser nozzle able to and designed to cut with a laser beamusing a reduced gas flow and/or gas pressure by virtue of a specialnozzle architecture, making it possible to force a large proportion ofgas to enter the kerf 31 and to effectively expel the molten metaltherein, and this whatever the laser power and wavelength of the beam.

According to the invention, the laser nozzle comprises at least twoessential components, namely a nozzle body 1 cooperating with a movableelement 2 arranged so as to be able to move inside the body 1 of thenozzle, one embodiment of which is illustrated in FIG. 2 and FIG. 3.

More precisely, as can be seen in FIG. 2, the nozzle body 1 that isformed from a conductive material, for example copper or brass, isintended be fixed to the laser focusing head 20 of the laserinstallation.

Advantageously, the nozzle body 1 is a part of revolution that haspassing right through it an axial housing 5 of axis AA that extends fromthe rear face 1 b to the body 1 as far as the front face 1 a of saidbody 1.

The axial housing 5 emerges at the two front 1 a and rear 1 b faces ofthe nozzle body 1. The rear face 1 b therefore carries a first inletorifice 11′ whereas the front face 1 a carries a first outlet orifice 11of the nozzle body 1, the first inlet 11′ and outlet 11 orifices beingcoaxial of axis AA.

This axial housing 5 is in fact a recess, for example cylindrical inshape, comprising an internal shoulder 9 projecting radially towards thecentre of the housing 5, said internal shoulder 9 being formed by arestriction 15 of the cross-section of the axial housing 5 at the firstoutlet orifice 11 situated on the front face 1 a of the nozzle body 1.

The nozzle of the invention moreover comprises a movable element 2inserted in the housing 5 of the nozzle body 1, as can be seen in FIG.3. This movable element 2 is able to and designed to move in translationalong the axis AA inside the housing 5 of the nozzle body 1.

More precisely, this movable element 2 comprises a front part 2 aforming a skirt 6, typically cylindrical in shape, that is to saytubular, arranged in the axial housing 5 of the nozzle body 1 andcomprising an axial passage 4 with a second outlet orifice 12 emergingat the front part 2 forming said skirt 6.

During use of the nozzle, the laser beam 22 and the assistance gas 23pass through the axial passage 4 of the movable element 2 and emergethrough the second outlet orifice 12 emerging at the front part 2forming said skirt 6.

The movable element 2 is preferentially formed from an insulatingmaterial, for example polyetheretherketone (PEEK), Vespel®, ceramic orPyrex.

The internal profile of the axial passage 4 of the movable element 2comprises, along the axis AA, an upstream portion 4 a of convergentfrustoconical form, i.e. the cross-section of which gradually reduces,followed by a downstream portion 4 b of divergent frustoconical form,i.e. the cross-section of which increases gradually until it forms theoutlet orifice 12 of the movable element 2.

Alternatively, the internal profile of the axial passage 4 of themovable element 2 also comprises an intermediate portion 4 c with acylindrical shape situated between the frustoconical upstream portion 4a and the frustoconical downstream portion 4 b of the internal profileof the axial passage 4.

The movable element 2 is movable axially with respect to the body 1 ofthe nozzle along the axis AA. In fact, the movable element 2 moves underthe effect of the pressure of the assistance gas 23 that is exerted onsaid movable element 2, which tends to push it in the direction of thepart to be cut 30.

The translational movement along the axis AA of the movable element 2will cause the skirt 6 to move closer to the top surface of the part 30to be cut. More precisely, the divergent frustoconical shape of thedownstream portion 4 b of the internal profile of the movable element 2is able to produce a controlled leakage of gas between the front part 2a of the movable element 2 and the top surface of the part 30 to be cut.This will assist the formation of a fine gas layer under the front part2 a, thus opposing the translation movement of the movable element 2towards the part to be cut 30 and holding the front part 2 a of themovable element 2 at a distance 32 of between 0.01 and 0.1 mm from thetop surface of the part to be cut 30.

Thus the gas will be channelled by the skirt 6 and be concentrated atthe laser spot and therefore the kerf, which will greatly improve itsefficacy and the expulsion of the metal will take place better.

Moreover, the fine gas layer formed by virtue of the downstream portion4 b of the internal profile of the movable element 2 makes it possibleto hold the front part 2 a of the movable element 2 at a distance 32 andtherefore to limit the contact of the insert with the metal sheet, thuspreventing any risk of scratching of the cut sheet. Naturally, thedownstream portion 4 b of the internal profile of the movable element 2is able to produce a controlled gas leakage that is sufficiently low topreserve the ability of the skirt 6 to concentrate the gas at the kerf.

According to the invention, an elastic element 8, such as a spring, isarranged in the axial housing 5, between the nozzle body 1 and themovable element 2 so as to exert an elastic return force on the movableelement 2 in a direction tending to move it away from the part to becut.

Thus, at the end of cutting, when the gas is cut and the gas pressureceases being exerted on the movable element 2, the latter can bereturned to its idle position and therefore the skirt 6 can completelyor almost completely retract inside the housing 5, as illustrated inFIG. 4B.

It is thus possible to effect rapid movements of the body of the nozzleabove the metal sheet, typically at a few mm from the sheet, preventingthe movable element projecting outside the housing 5, or greatlylimiting the portion of skirt projecting outside the housing 5, andtherefore without risking damaging the movable element 2, in particularthe front part 2 a.

The nozzle of the invention also makes it possible to perform piercingoperations with a low gas pressure without the movable element 2projecting outside the housing 5 or greatly limiting the portion ofskirt 2 a projecting outside the housing 5. The return force of theelastic element 8 is then advantageously sized so that a gas pressureranging preferably up to 4 bar is not sufficient for the movable element2 to move in translation towards the metal sheet. It is thus avoideddamaging the inside of the movable element 2 and the front part 2 a.

Finally, the present invention makes it possible for the movable element2 to be able to be moved away from the metal sheet, without having tolift the focusing head supporting the nozzle of the invention, that isto say moving it away from the metal sheet.

It should be noted that the external peripheral wall of the movableelement 2 comprises a stop 10, preferably an annular stop extending overall or part of the periphery of said movable element 2, the elasticelement 8 being positioned between the shoulder 9 and the stop 10.

In fact, the movable element 2 of the nozzle according to the inventionis therefore able to move between several positions comprising at least:

-   -   an idle position in which the skirt 6 of the front part 2 a is        completely or almost completely retracted in the axial housing 5        of the nozzle body 1, as illustrated in FIG. 4B, and    -   a working position in which the skirt 6 of the front part 2 a        projects completely or almost completely outside the axial        housing 5 of the nozzle body 1, through the first outlet orifice        11, and comes at a distance 32 from the top surface of the part        30 to be cut, as illustrated in FIG. 4A.

Naturally, the movable element 2 can occupy intermediate positions inwhich the skirt 6 only partially projects outside the axial housing 5 ofthe nozzle body 1. These intermediate positions may in particular dependon the pressure exerted by the gas on the movable element 2.

Moreover, at least one sealing element 7 is arranged between the nozzlebody 1 and the movable element 2, in particular one or more O-ring seals7, which provides a seal between the nozzle body 1 and the movableinsert 2.

As can be seen in FIG. 3, the nozzle of the invention is of standardsize, that is to say its size is not increased compared with aconventional nozzle body, which is advantageous and compatible for cutsby interleaving, that is to say parts within the same metal sheet withvery little separation between the various parts.

In addition, the nozzle of the invention has the other advantage ofbeing compatible with capacitive sensor systems. This is because thepart made from copper or other conductive material adapts to the heightspecified by the capacitive sensor, like a standard nozzle. It is themovable insert 2 which, under the pressure of the gas, comes close tothe sheet 30 to be cut and thus limits gas leakages.

The nozzle of the invention comprises a movable element 2 the outletorifice diameter 12 of which is preferably between 0.5 and 5 mm.

EXAMPLES

In order to show the efficacy of the nozzle according to the inventioncompared with a standard nozzle, and therefore the advantage of forcingthe gas into the cutting groove by virtue of the use of a skirt mountedon a movable element, comparative tests were carried out using a cuttinginstallation with a laser generator of the CO₂ type for generating alaser beam that is brought to a laser focusing head comprising focusingoptics, namely lenses.

The laser focusing head is equipped, according to circumstances, with astandard nozzle with an outlet orifice 1.8 mm in diameter or a nozzleaccording to FIG. 3 with a cylindrical movable skirt 1.8 mm in diameter.

The assistance gas used is nitrogen.

The cut part is a 304 L stainless steel sheet 5 mm thick.

The laser beam has a power of 4 kW and the cutting speed is 2.6 m/min.

The results obtained showed that:

-   -   with the standard nozzle, a gas pressure of 14 bar is        insufficient to obtain a quality cut. This is because, at 14        bar, the cut edges comprise numerous adherent burrs. This        demonstrates that the discharge of the molten metal is badly        done because of an insufficient action of the gas on the molten        metal that has to be expelled. In order to eliminate these        burrs, a pressure of 16 bar was necessary;    -   with the nozzle of the invention, tests carried out at pressures        ranging between 1 and 5 bar led to cuts of good quality, that is        to say with cutting edges devoid of adherent burrs. The skirt of        the nozzle makes it possible to channel the gas into the groove        and to effectively expel the molten metal. The top surface of        the cut sheet is free from scratches.

These tests demonstrate clearly the efficacy of a nozzle according tothe invention, which makes it possible to considerably reduce the gaspressures to be used compared with a standard nozzle, all otherconditions being equal, and therefore also to reduce gas consumptions.

It will be understood that many additional changes in the details,materials, steps and arrangement of parts, which have been hereindescribed in order to explain the nature of the invention, may be madeby those skilled in the art within the principle and scope of theinvention as expressed in the appended claims. Thus, the presentinvention is not intended to be limited to the specific embodiments inthe examples given above.

What is claimed is:
 1. A laser nozzle comprising: a nozzle bodycomprising a front face, and an axial housing axially passing throughsaid nozzle body and comprising a first outlet orifice situated at thefront face of the nozzle body, a movable element arranged in the axialhousing of the nozzle body comprising a front part forming a skirt andan axial passage with a second outlet orifice emerging at the front partforming a skirt, said movable element being able to move in translationin the axial housing due to a gas pressure exerted on the movableelement, wherein the second outlet orifice comprises an internal profilewith a divergent frustoconical shape, wherein the divergentfrustoconical shape is configured to produce a controlled leakage of thegas between the skirt and a surface of a part to be cut, and wherein thecontrolled leakage is configured to assist in the formation of a finegas layer under the skirt, which opposes the translation movement of themovable element, and holding the skirt a predetermined distance abovethe surface of the part to be cut.
 2. The nozzle of claim 1, wherein thegas is concentrated by the skirt at the laser spot and thus the kerf,and thus improving cutting efficiency and metal expulsion.
 3. The nozzleof claim 1, wherein of the first outlet orifice situated at the frontface of the nozzle body, the front part forming a skirt of the movableelement projects outside the axial housing through the first outletorifice of the front face of the nozzle body.
 4. The nozzle of claim 1,wherein the movable element is able to move in translation in the axialhousing until the front part forming a skirt of the movable elementprojects outside the axial housing through the first outlet orifice ofthe front face of the nozzle body.
 5. The nozzle of claim 1, wherein atleast one sealing element is arranged between the nozzle body and themovable element.
 6. The nozzle of claim 1, wherein the movable elementis able to move between several positions comprising: an idle positionin which the skirt of the front part is totally or almost totallyretracted in the axial housing of the nozzle body, and a workingposition in which the skirt of the front part totally or almost totallyprojects outside the axial housing of the nozzle body, through the firstoutlet orifice.
 7. A laser focusing head comprising at least onefocusing lens, further comprising a laser nozzle according to claim 1.8. A laser installation comprising a laser generator, a laser focusinghead and a laser beam conveying device connected to said laser generatorand to said laser focusing head, the laser focusing head is inaccordance with claim
 7. 9. The installation of claim 8, wherein thelaser generator is of the CO₂ or YAG type, with fibres or discs.